BONE FIXATION MEMBER SYSTEMS AND METHODS OF USE

• US 20130261625A1
• Filed: 03/13/2013
• Published: 10/03/2013
• Est. Priority Date: 03/28/2012
• Status: Active Grant

• Current Assignee: Depuy Synthes Products Incorporated (Johnson & Johnson)
• Original Assignee: Depuy Synthes Products Incorporated (Johnson & Johnson)
• Inventors: Koch, Rudolf, Knueppel, Stefan, Schmitt, Raymond, Martella, Arthur T.
• Granted Patent: US 9,585,705 B2
• Time in Patent Office: Days
• US Class Current: 606/74
• CPC Class Codes: A61B 17/1604 Chisels; Rongeurs; Punches; Stamps
• CPC Class Codes: A61B 17/1611 the two jaw elements being integral with respective elongate shaft elements
• CPC Class Codes: A61B 17/1691 for the sternum
• CPC Class Codes: A61B 17/82 for bone cerclage apparatus for manipulating wires or straps A61B17/8861; wires, bands or straps other than cerclage A61B17/842
• CPC Class Codes: A61B 17/823 for the sternum
• CPC Class Codes: A61B 17/8861 Apparatus for manipulating flexible wires or straps devices for inserting Kirschner wires A61B17/1697
• CPC Class Codes: A61B 17/8863 Apparatus for shaping or cutting osteosynthesis equipment by medical personnel
• CPC Class Codes: A61B 17/8869 Tensioning devices
• CPC Class Codes: A61B 2017/00407 Ratchet means
• CPC Class Codes: A61B 90/03 Automatic limiting or abutting means, e.g. for safety

Abstract

A bone fixation member can be configured to secure first and second bone segments of a target bone together in a compressed approximated position. The bone fixation member can include a strap made of a first material, a locking head extending from a proximal end of the strap, and a leader portion extending from a distal end of the strap. The locking head can have a housing and a strap receiving slot that extends through the housing, slot is configured to receive a distal end of the strap. The housing can be tapered such that a distal end of the housing has a thickness that is greater than the thickness of a proximal end of the housing. The leader portion can be configured to be more flexible than the strap. The leader portion can be made of a second material that is different than the first material.

Claims

1. A bone fixation kit comprising at least one bone fixation member that is configured to compress first and second bone segments in an approximated position, the at least one bone fixation member comprising:

an elongate strap made of at least a first material and having a plurality of teeth;

a locking head that extends from the strap along a first direction, the locking head having a housing, a strap receiving slot that extends through the housing, and a toothed locking member that extends into the strap receiving slot such that when the strap is inserted through the strap receiving slot along an insertion direction, the toothed locking member engages at least one of the teeth to prevent the strap from translating through the strap receiving slot along a direction that is opposite the insertion direction;

a leader portion that extends from the strap along a second direction opposite the first direction, wherein the leader portion is made of at least a second material that is different than the first material, such that the leader portion is more flexible than the strap; and

a needle that extends from the leader portion such that the leader portion is connected between the strap and the needle.

2. The bone fixation kit of claim 1, wherein the strap defines a distal end and a proximal end spaced from the distal end along the first direction, the strap having a first length measured from the proximal end to the distal end, and the leader portion having a second length measured along the first direction that is at least 25% of the first length.

3. The bone fixation kit of claim 2, wherein the second length is between about 100 mm and about 300 mm.

4. The bone fixation kit of claim 1, wherein the leader portion has a diameter that is between about 0.6 mm and about 1.5 mm.

5. The bone fixation kit of claim 1, wherein the second material is stainless steel.

6. The bone fixation kit of claim 1, wherein the first material is PEEK or PEKK.

7. The bone fixation kit of claim 1, wherein the strap further includes a metal insert disposed at the distal end of the strap, the leader portion being coupled to the metal insert by a weld.

8. The bone fixation kit of claim 1, wherein the locking head defines a first end and a second end that is spaced from the first end along a third direction that is perpendicular to the first direction, the first end being tapered along the first direction.

9. The bone fixation kit of claim 8, wherein a distance measured along the third direction from an upper most portion of the first end to a lower most portion of the second end is no more than 1.5 times a thickness of the strap measured along the third direction.

10. The bone fixation kit of claim 8, wherein the locking head includes a cap that defines the first end.

11. The bone fixation kit of claim 1, further comprising a cap that is separate from the locking head, the cap defining a cavity that is configured to receive at least a portion of the locking head so as to overlie at least a portion of the locking head.

12. The bone fixation kit of claim 11, wherein the cap includes a cap body that defines a distal body end and a proximal body end that is opposite the distal body end along the first direction when the cap is coupled to the locking head, the cap body further defining first and second ends that are spaced from each other along the insertion direction when the cap is coupled to the locking head, wherein the first end of the cap body is curved along a direction from a location between the distal body end and the proximal body end toward the proximal body end.

13. The bone fixation kit of claim 12, wherein the curved first end of the cap body is tapered.

14. The bone fixation kit of claim 12, wherein the cap body further includes an opening that extends through the distal body end and into the cavity, the opening configured to receive the strap when the cap is coupled to the locking head.

15. The bone fixation kit of claim 12, wherein the cap body defines an outer shell and an inner shell disposed within the outer shell, the inner shell defining the cavity.

16. The bone fixation kit of claim 15, wherein the outer shell defines an inner surface and the inner shell defines an outer surface that faces and is spaced apart from the inner surface such that the inner shell is configured to flex outwardly as the cavity receives the locking head.

17. The bone fixation kit of claim 11, wherein the cap further includes at least one attachment member that is configured to couple the cap to the locking head.

18. The bone fixation kit of claim 1, further comprising a bone punch configured to form a hole in at least one of the first and second bone segments.

19. The bone fixation kit of claim 18, wherein the first and second bone segments are first and second portions of a manubrium and the bone punch is configured to form a respective hole in each of the first and second portions from an anterior approach.

20. The bone fixation kit of claim 19, wherein the bone punch includes a boom arm that is elongate along a punch direction, the boom arm defining a proximal punch housing and a distal punch housing spaced from the proximal punch housing along the punch direction such that a bone receiving gap is defined between the proximal and distal punch housings, the bone punch further including a needle having a bone engaging tip, the needle being translatable along the punch direction between a first position whereby the tip is proximal to the bone receiving gap, and a second position whereby the needle extends through the bone receiving gap and toward the distal housing.

21. The bone fixation kit of claim 20, wherein the proximal punch housing includes a plurality of support members that house the needle such that the needle is translatable between the first and second positions.

22. The bone fixation kit of claim 21, wherein the tip extends into the distal housing when the needle is in the second position.

23. The bone fixation kit of claim 20, wherein the bone receiving gap is sized to receive the manubrium such that when the bone receiving gap has received the manubrium the punch direction is substantially perpendicular to an anterior surface of the manubrium.

24. The bone fixation kit of claim 20, wherein the bone engaging tip is pyramid shaped.

25. A bone fixation kit comprising at least one bone fixation member configured to compress first and second bone segments of a target bone together in an approximated position, the at least one bone fixation member comprising:

a strap that is elongate along a first direction and defines a proximal strap end, and a distal strap end spaced from the proximal strap end along the first direction, the strap having a plurality of teeth;

a locking head that defines a distal head end that extends from the proximal strap end, and a proximal head end that is opposite the distal head end, the locking head defining opposed first and second ends that are spaced along a second direction that is substantially perpendicular to the first direction, and a strap receiving slot that extends through the locking head along the second direction, the locking head further including a toothed locking member that extends into the strap receiving slot and is configured to engage at least one of the teeth when the strap is inserted through the strap receiving slot along an insertion direction so as to prevent the strap from translating through the strap receiving slot along a direction that is opposite the insertion direction, the locking head being tapered along a direction from the distal head end toward the proximal head end so as to define a first thickness at the distal head end measured along the second direction and a second thickness at the proximal head end measured along the second direction that is less than the first thickness; and

a needle coupled to the distal strap end.

26. The bone fixation kit of claim 25, wherein the at least one bone fixation member further comprises a leader portion that extends between the distal end of the strap and the needle, wherein the leader portion is made from a different material than that of the strap.

27. The bone fixation kit of claim 25, wherein the strap defines an upper surface and the first end of the locking head defines an upper surface, and a maximum distance measured between the upper surface of the strap and the upper surface of the locking head along the second direction is less than about 2.4 mm.

28. The bone fixation kit of claim 25, wherein the first end defines an upper surface that is convex along the first direction.

29. The bone fixation kit of claim 28, wherein the second end defines a lower surface that is concave along the first direction.

30. The bone fixation kit of claim 25, wherein a slope of the upper surface increases at a first rate, and a slope of the lower surface increases at a second rate that is substantially less than the first rate.

31. The bone fixation kit of claim 25, wherein a distance measured along a second direction that is perpendicular to the first direction from an upper most portion of the first end to a lower most portion of the second end is no more than 1.5 times a thickness of the strap measured along the second direction.

32. The bone fixation kit of claim 25, wherein the toothed locking member includes three complementary teeth that each extend into the strap receiving slot.

33. The bone fixation kit of claim 25, further comprising a bone punch configured to form a hole in at least one of the first and second bone segments.

34. The bone fixation kit of claim 33, wherein the first and second bone segments are first and second portions of a manubrium and the bone punch is configured to form a respective hole in each of the first and second portions from an anterior approach.

35. The bone fixation kit of claim 34, wherein the bone punch includes a boom arm that is elongate along a punch direction, the boom arm defining a proximal punch housing and a distal punch housing spaced from the proximal punch housing along the punch direction such that a bone receiving gap is defined between the proximal and distal punch housings, the bone punch further including a needle having a bone engaging tip, the needle being translatable along the punch direction between a first position whereby the tip is proximal to the bone receiving gap, and a second position whereby the needle extends through the bone receiving gap and toward the distal housing.

36. The bone fixation kit of claim 35, wherein the proximal punch housing includes a plurality of support members that house the needle such that the needle is translatable between the first and second positions.

37. The bone fixation kit of claim 36, wherein the tip extends into the distal housing when the needle is in the second position.

38. The bone fixation kit of claim 35, wherein the bone receiving gap is sized to receive the manubrium such that when the bone receiving gap has received the manubrium the punch direction is substantially perpendicular to an anterior surface of the manubrium.

39. The bone fixation kit of claim 35, wherein the bone engaging tip is pyramid shaped.

40. The bone fixation kit of claim 25, wherein the locking head is a single monolithic unit.

41. The bone fixation kit of claim 25, wherein the locking head includes a housing and a cap coupled to the housing such that the cap defines the first end of the locking head.

42. The bone fixation kit of claim 41, wherein the cap defines a cavity that is configured to receive at least a portion of the housing so as to overlie at least a portion of the housing.

43. A method of forming holes in first and second sternal portions with a bone punch, the bone punch including a boom arm that is elongate along a punch direction, and a needle that is coupled to the boom arm and translatable relative to the boom arm along the punch direction between a first position and a second position, the method comprising:

positioning the bone punch such that the first sternal portion is received in a bone receiving gap defined by the boom arm and the punch direction is substantially perpendicular to an anterior surface of the first sternal portion;

causing the needle to translate from the first position to the second position such that the needle passes through the first sternal portion along the punch direction to thereby form a hole in the first sternal portion;

causing the needle to translate from the second position to the first position; and

removing the bone punch from the first sternal portion.

44. The method of claim 43, further comprising:

positioning the bone punch such that the second sternal portion is received in the bone receiving gap and the punch direction is substantially perpendicular to an anterior surface of the second sternal portion;

causing the needle to translate from the first position to the second position such that the needle passes through the second sternal portion along the punch direction to thereby form a hole in the second sternal portion;

causing the needle to translate from the second position to the first position; and

removing the bone punch from the second sternal portion.

45. The method of claim 43, wherein the first and second sternal portions are first and second portions of the manubrium.

46. The method of claim 43, wherein the positioning step comprises:

positioning a distal portion of the boon arm into a fracture that separates the first bone segment from the second bone segment; and

rotating the boom arm so that the bone receiving gap receives the first bone segment.